SPI 2014 Overview of the Proposed PV Quality Management System

Transcription

1 SPI 2014 Overview of the Proposed PV Quality Management System Task Group 1- Govind Ramu SunPower Corp., San Jose, CA 2014 SunPower Corporation

2 About the Presenter Dire ctor of Glob al Quality Management Systems, SunPower Corp. More than 25 years of experience implementing quality management syste m s in variou s glob al location s from variou s industry sectors US TAG TC 176/SC2 participating member for ISO 9001:2015 standards Expert on IEC TC 82 WG 2- Solar p h otovoltaic e n e rgy syste m s- Modules- non concentrating A licensed professional engineer in the province of Ontario, Canada, mechanical engineering degree from Bangalore University, India An ASQ Fe llow, h old s six ASQ ce rtification s: q u ality m an age r, q u ality e n gin e e r, Six Sigm a Black Belt, quality auditor, software quality engineer and reliability engineer Has coauthored ASQ s Certified Six Sigma Green Belt Handbook, one of the major contributing authors for The Lean Certification Handbook Served as an examiner in 2006, 2011, and 2012 for the California Awards for Performance Excellence (CAPE) and as an Examiner for the Malcolm Baldrige National Quality Award in

3 Table of Contents Why Quality Management System (QMS)? Introduction to ISO 9001 Audits and Certification PV QMS Standard timeline Why Industry standard? PV QMS Requirements Brief review of key requirements ISO 9001-What next? PV QMS- Fu tu re p ossib ilitie s (b ra in storm in g session s to follow) Appendix 3

4 ISO 9001 Quality Management System Requirements More than 25 years of evolution since its inception in Cove rs general and foundational quality management requirements applicable to any industry or service sectors ISO 9001 is now a contractual requirement for many organizations worldwide, often prerequisite for bidding new tenders ISO 9001 is im p le m e n te d in ove r m illion organ izations world wid e 4

5 Types of System Audits First party audit: Organization use the standard to verify compliance. Also known as Internal quality systems audit Second party audit: Organization use the standard to verify compliance of their suppliers quality systems Third party audit: An independent organization (registrar) verify compliance to the standard to issue ISO 9001 certificate for a client An accreditation body audits the registrars to verify their ability to issue ISO 9001 certificates Audit verify compliance to standard, organization s QMS, an its effectiveness. 5

6 Certification Process Stage 1 audit- Registrar auditors verify compliance to the standard as a desk audit and review overall QMS fram ework Stage 2 audit- Registrar auditors verify compliance to the standard by auditing processes covered in the scope of registration Once certificate is issued, registrars conduct p e riod ic surve illan ce au d it annually, conduct re ce rtification audit every 3 years Du e d ilige n ce all th e way 6

7 Highlights of QMS Requirements for PV Module Manufacturing- Ta s k Group 1

8 Why Industry specific standard? Generic nature of ISO 9001 requirements Inconsistent use of Exclusion clause from ISO 9001users No requirements to apply specific proven controls (FMEA, Control Plan, SPC, Mistake p roofin g, e tc.) Requirements not addressing PV industry specific expectations ISO 9001 alone may not be adequate to address industry specific requirements 8

9 Industry Specific QMS Standards Started from Mid-1990s TS Automotive AS9100- Ae ro s p a ce ISO Biom e d ical TL Te le com m u n ication Service sectors are also developing QMS standards to address specific requirements. Best Practices from industries: Telecom- Metrics submission and reporting (Double blind process) Supply Chain Practices in Aerospace Production Part Approval Process (PPAP) in Automotive. Other industry sectors are very successful in development and deployment of standards 9

10 PV QMS Standard Development Timeline METI approaches DOE t oward international PV QA effort International PV Module QA Forum San Francisco PV Module Reliability Workshop Golden, Denver Submission of CD Com m ents t o IEC Dec 2010 Ju l y 2011 Ju l y 2011 Sep 2011 Oct 2013 Feb 2014 Oct 2014 Highlighted the need to strengthen the QM program used by the PV module manufacturer, conclusion was to adopt the two primary goals and form the five Task Groups. The International PV Module Quality Assurance Task Force was formed 5 Task groups formed, Task Group 1- Responsible for PV QMS. Task Group #1 began to write a PV-specific version of ISO 9001 supplementary requirements. National Committees of IEC TC82 WG2 as the New Work Item Proposal 82/800/NP. 10

11 PV QMS Key requirements PV module s design to align the expected life tim e Product realization that includes appropriate certification, qualification, including both type approval and safety testing Product traceability through the entire supply and delivery chain Ongoing, periodic monitoring program to ensure consistency of aspects of manufacturing Special Process controls Power rating tolerance Resource Management Closed loop learning from field information Supplier Management Manufacturing and testing Process auditing Use Statistical methods, sampling 11

12 PV QMS Requirements A method for selection of vendors that can provide quality materials or products Receiving inspection and/or testing such as statistical sampling based on performance. Ensure that the supplier maintains product quality consistently, and will notify and seek approval when there is any change of products, process, manufacturing location or significant process excursion that may affect form, fit, function, reliability or performance Controls:. Periodic supplier audits Performance monitoring Traceability requirements 12

13 PV QMS Power Rating Assignment of PV module power rating with allowed tolerance including measurement uncertainty Controls: Determine parameter sets for the acceptance tolerance Determine measurement uncertainty 13

14 PV QMS Requirements - Traceability Requirement to improve product traceability through the entire supply and delivery chain to enact positive control of the product for recalls and warranty claims Controls: constituent key materials and components lot/batch level Traceable to supplier, date, Mfg. location Traceable to Internal processes, process conditions, equipment Traceable to operators (manual processes) Reworked/repaired products 14

15 PV QMS Requirement Design controls Focus on the organization s control of the PV module s design to align the expected lifetime with its relationship to the organization s warranty Controls: Design FMEA Reliability testing, periodic testing, Long term outdoor testing, etc. Lessons learned Closed loop learning 15

16 Design at the Source: Factor of 10 Thumb Rule The cost of addressing reliability issues increases tenfold as you move through the development process Courtesy: SunPower Corporation New Employee Orientation material 16

17 PV QMS Requirements - Certification A product realization that includes appropriate certification (e.g. IEC qualification, including both type approval and safety testing), a design lifetime that enables alignment with warranty Controls: Design FMEA/ Risk assessment Internal/external testing and qualification Certification Warranty modeling Customer return FA 17

18 PV QMS Requirements - Reliability An ongoing, periodic monitoring program to ensure consistency of aspects of manufacturing that may affect safety, performance, and reliability Controls: Control Plan Statistically adequate sampling Reliability Monitoring Program (RMP) 18

19 PV QMS Special Processes Special processes such as control of solder connections Control of processes for ESD protection ESD- Electrostatic Discharge (ESD) safe environment at the raw material storage, processing, assembly areas, as appropriate Controls: Process qualification, critical controls identification, operator qualifications Software validation ESD Program audit 19

20 PV QMS Resource Management Resources needed to maintain the product warranty system, product reliability measurements, provision of after-sales service Succession planning for key functions that affect customer, quality reliability, safety and performance Controls: Product warranty database management system Technical support resources Succession planning, periodic review 20

21 PV QMS Requirements Previous failure information incorporated into the requirements of the QMS Controls: Failure information database management Closed loop learning Updated DFMEA, Design Review 21

22 PV QMS Requirements manufacturing and testing Routine tests on 100% of product to ensure consistency of initial quality Manufacturing feasibility at the necessary scale, including risk analysis Control plan for solar simulators and how they are used in the performance rating of modules Controls: Process FMEA Control Plan Measurement System Analysis uncertainty calculations 22

23 9001 Vs PV QMS- Product- Process- System Audits Sy st em Audit (E.g. ISO 9001) Process Audit (PV QM S) Product Audit (PV QM S) 23

24 PV QMS Use appropriate statistical tools and statistically significant sample sizes to make decisions that affect quality of process and products at all stages of the lifecycle Use of error proofing, Statistical process Control, control plan, Failure mode effects analysis, and 8 Discipline methodology to build PV modules with consistent quality and re lia bility Controls: Proce ss FMEA Poke Yoke Control Pla n SPC 8D methodology 24

25 What is next in ISO 9001 (2015)? Standard becoming more generic to cater all industry types including service sector. Mandatory documentation requirements for some process go away (Even more so why we need PV Industry specific QMS!) Risk based thinking-leveraged with leadership managing risks when m akin g organ ization al d e cision s. (adding good foundation) Knowledge Management (aligns with closed loop learning in PV QMS) Sp e cific requirements for adopting the process approach*. (adding good foundation to process audits) (Standard currently at draft stage. Standard expected by Sep 2015) *See appendix 25

26 References, Bibliography & Acknowledgements References: ISO 9001:2008 Quality Management System requirements 82/800/NP- Guideline for increased confidence in PV module design qualification and type approval. JIS Q 8901:2012- Te rre strial photovoltaic (PV) modules -- Requirement for reliability assurance system (design, production and product warranty) Bibliography: ISO 19011:2011 Guidelines for auditing management systems Tip of the iceberg- Qu ality Progre ss article, May 2001 Acknowledgement: Ms. Sarah Ku rtz, Re liab ility Group Man age r, Prin cip al Scie n tist, Ph D, National Renewable Energy Laboratory, Golden, CO Task Group 1 International team members SunPower Corporation, San Jose, CA USA Quality, Reliability & Management 2014 SunPower Corporation. All Rights Re serve d. SUNPOWER and the SUNPOWER logo are trademarks or registered trademarks of SunPower Corporation in the U.S. and other countries as well. 26

27 Thank You Let s change the way our world is powered SunPower Corporation

28 Appendix

29 PV QMS future Possibilities (Brainstorm ideas) PV design, manufacturing and service metrics periodic submission to a vetted third party for analysis and publication of Best in class, top decile, median values (with anonymity- double blind process) for industry benchmarking PV QMS exte n d e d to sup p lie rs of key m ate rials ( Sim ilar to PPAP from Au tom otive industry) PV QMS transition to PV IMS Integrated Management system to include Environmental, occupation health and safety requirements for PV manufacturing Graded approach to PV QMS audit outcome based on maturity levels. Audits go beyond compliance Exchange of epidemic failure information by PV technology Benchmark QMS practices with other well established industry sectors (e.g. Automotive, Telecom, Aerospace) 29